Attachment element for use with concrete wall and method employing same

ABSTRACT

An attachment element for use with a concrete wall construction that includes a layer of concrete and a layer of an insulative material that is held against a face of the layer of concrete. The attachment element includes an elongated body member having a first portion that is adapted and arranged for embedment in the layer of concrete as the latter hardens and a second portion that is positioned longitudinally of the body member from the first portion. The second portion is adapted and arranged so as to extend outwardly from the face of the concrete and through a closed slot formed in the layer of insulative material. The attachment element also includes an elongated face plate that is attached to the second portion of the body member adjacent an outer end of the latter. The face plate is positioned so as to extend transversely of the body member and the same is adapted and arranged at the outer surface of the layer of insulative material in a position to extend laterally outwardly away from the body member and across the outer surface beyond the periphery of the slot. The entirety of the attachment element other than the face plate is small enough in size to permit insertion thereof through the slot during use.

BACKGROUND OF THE INVENTION

[0001] 1. The Field of the Invention

[0002] The present invention relates generally to insulated concretewall structures, and more particularly to attachment elements which areuseful in connection with such wall structures both for attachingmaterials such as decorative materials thereto and for holding theinsulative material in place against the concrete wall during furtherconstruction activities.

[0003] 2. The State of the Prior Art

[0004] Prior U.S. Pat. No. 5,987,830 (hereinafter, “the '830 patent”),describes an insulated concrete wall structure that comprises a layer ofconcrete and a layer of an insulative material. Such structures may beformed using conventional aluminum forms. In particular the wallstructure may be formed using a tie assembly for holding the forms andthe layer of insulative material in place while concrete is poured andallowed to harden. The tie assembly may include an attached face platethat is held in position against the outer face of the layer ofinsulative material. This face plate may be formed of a suitablesynthetic resin material capable of receiving threaded screws or thelike such that the face plate may then be used as an attachment site forattaching decorative and/or finishing materials or the like to the wallstructure. A problem with this prior art arrangement is that thelocation of the attachment sites is determined more by the needs of theform assembly than by the needs of the finishing operation. Thus, theattachment sites are not always positioned correctly for optimization ofthe finishing operation. Moreover, the prior art ties are made of aplurality of parts which must be assembled at the job site. The entiretyof the '830 patent is hereby incorporated herein by this specificreference thereto, for purposes of supplementing the followingdisclosure.

SUMMARY OF THE INVENTION

[0005] In its broadest aspects the invention provides solutions forand/or relief from the prior art problems discussed above. Moreover, theinvention provides a simple device which simplifies the construction ofconcrete wall structures and facilitates the attachment of finishingand/or decorative materials to a concrete wall structure. In accordancewith the concepts and principles of the invention, an attachment elementis provided for use with a concrete wall structure that includes a layerof concrete and a layer of an insulative material that is held against aface of the layer of concrete. The layer of insulative material has aninner surface which is in contact with the concrete face and an outersurface which is spaced from the concrete face. The concrete is ofcourse characterized by having been initially fluid and having hardenedwith the face thereof in the contact with the inner surface of the layerof insulative material.

[0006] In further accordance with the concepts and principles of theinvention, the attachment element may include an elongated body memberhaving a first portion that is adapted and arranged for embedment in thelayer of concrete as the latter hardens and a second portion positionedlongitudinally of the body member from the first portion. The secondportion may be adapted and arranged so as to extend outwardly from theface of the concrete layer and through a closed slot formed in the layerof insulative material. Generally speaking, such a slot will have anouter periphery at the outer face of the insulative layer. Theattachment element may also include an elongated face plate attached tothe second portion adjacent an outer end of the latter. Such face platemay desirably be positioned so as to extend transversely of the bodymember and adapted and arranged at the outer surface of the layer ofinsulative material in a position to extend laterally outwardly awayfrom the body member and across the outer surface beyond the peripheryof the slot. Thus, the face plate may be operable for holding the layerof insulative material against the layer of concrete. For ease ofassembly, the entirety of the attachment element other than the faceplate should be small enough in size to permit insertion thereof throughthe slot during use. Desirably the body member and the face plate may beintegrally connected. The portions of the body member may also beintegrally connected. Ideally, the attachment element may be monolithic.The attachment element may also ideally have a generally T-shapedtransverse cross-sectional configuration.

[0007] Desirably, the second portion of the body member may be in theform of a sheet having opposed surfaces, and ideally the sheet may begenerally planar in configuration. For improved functionality, theattachment element may have one or more ribs which protrude laterallyoutwardly from one or both surfaces of the sheet, and ideally the ribsmay have generally rounded outer surfaces. In addition, in a highlypreferred form of the invention, the second portion may include ananchor segment located at the face of the concrete layer, and suchanchor segment may be adapted and configured to retain the secondportion of the body member and thereby the attachment element in theconcrete. Desirably, the anchor segment may include a wing which extendslaterally outwardly from a surface of the sheet. Ideally, the wing mayinclude a beveled surface at an outer edge thereof which defines adovetail permitting the wing to be embedded in the layer of concreteduring construction.

[0008] In further accordance with the concepts and principles of theinvention, the face plate may desirably be formed from a material thatis adapted for receiving and retaining a fastener. Thus, the face platemay provide a site for attachment of finishing and/or decorativematerial to the wall structure. Such material may preferably be asynthetic resin material. Ideally, for ease of manufacture, the materialfrom which the attachment element is formed may be an extrudablethermoplastic material.

[0009] In accordance with another important aspect of the invention, thesame provides a concrete wall structure which includes a layer ofconcrete having a face and a layer of an insulative material which isretained against the layer of concrete. In accordance with this form ofthe invention, the layer of insulative material may desirably have aninner surface which faces the face of the layer of concrete and an outersurface that is spaced from the concrete layer. In further accord withthe concepts and principles of the invention, there may be at least oneclosed slot that extends through the thickness of the layer ofinsulative material from the inner surface to the outer surface, andsuch slot may have an outer periphery at the outer surface of theinsulative layer. The concrete wall structure further may include anattachment element as described above. Thus, the first portion of thebody member is embedded in the layer of concrete, the second portion ofthe body member protrudes outwardly of the layer of concrete from theface and through the slot, and the elongated face plate extendstransversely of the body member across the outer surface of the layer ofinsulative material. Desirably, depending upon the thickness of theinsulative layer and the positioning of the attachment element, thelatter may assist in holding the insulative layer against the layer ofhardened concrete. Preferably, the layer of insulative material mayconsist of at least one insulative panel that has opposed side edges andopposed top and bottom edges, and the slot is positioned somewhere inthe central portion of the panel in spaced relationship relative to saidedges.

[0010] Ideally, the concrete wall structure of the invention may includea decorative and/or finishing material or the like applied against theouter face of the panel of insulative material and secured thereto atleast in part by a fastener extending into the face plate.

[0011] In another important form of the invention, a method is providedfor constructing an insulated concrete wall structure. In accordancewith the broad concepts and principles of the invention, the method mayinclude the steps of providing an attachment element as set forth above,forming at least one slot in a panel of insulative material havingopposed first and second surfaces, the slot extending through the panelbetween the surfaces, inserting the body member of the element throughthe slot so that the first portion extends outwardly a preselecteddistance from the first surface of the panel of insulative material andthe face place is against the second surface of the panel of insulativematerial, applying a layer of fluid concrete against the first surfacein a position where the first portion of body member is surrounded bythe fluid concrete, and allowing the concrete to set to thereby form aninsulated concrete wall structure in which the first surface of thepanel of insulative material is against the hardened concrete, the firstportion of the body member of the attachment element is embedded in thehardened concrete, the second portion of the body member of theattachment element extends through the slot, and the face plate of theattachment element extends across the second surface of the panel ofinsulative material.

[0012] The method of the invention may desirably include a step ofsecuring a piece of decorative and/or finishing material or the like tothe wall structure by extending a fastener through the decorative and/orfinishing material and into the face plate of the attachment element.Ideally the insulative material may be heat deformable and the formingof the slot may include applying heat to the insulative material. Thus,a hot knife or the like may be used to cut a slot in a panel of plasticfoam material. In some preferred forms of the invention, a plurality ofslots may be provided in the insulative material and there may be arespective attachment element placed in each of the slots prior to theapplication of the layer of fluid concrete.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] In the accompanying drawings which form part of the specificationand are to be read in conjunction therewith and in which like referencenumerals are used to indicate like parts in the various views:

[0014]FIG. 1 is a fragmentary elevation view, taken in vertical section,of an insulated concrete wall in which an attachment element of thepresent invention is partially embedded;

[0015]FIG. 2 is a perspective view of the attachment element shown inFIG. 1;

[0016]FIG. 3 is a top plan view of the attachment element;

[0017]FIG. 4 is a fragmentary plan view, taken in horizontal section, ofan insulated concrete wall complete with a finishing panel attached tothe attachment element;

[0018]FIG. 5 is a perspective view to illustrate the manner in which theattachment element is inserted into a layer of insulation duringconstruction;

[0019]FIG. 6 is a top plan view to illustrate a method for constructingthe insulated concrete wall of FIG. 1; and

[0020]FIG. 7 is a schematic elevational view illustrating a layer ofinsulation useful in connection with the concrete wall of FIG. 1 andincluding an arrangement of several panels of insulation and a pluralityof attachment elements.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0021] Referring now to the drawings in greater detail, an insulatedwall 20 which embodies the concepts and principles of the invention isillustrated in FIG. 1. Thus, the wall 20 includes a layer of concrete 22and a layer of an insulative material 24 that is held against a face 26of the layer of concrete. The layer of insulative material 24 has aninner surface 28 which is in contact with the face 26 and an outersurface 30 which is spaced from the face. The concrete, of course, ischaracterized by having been initially fluid and having hardened withthe face 26 thereof in the contact with the inner surface 28 of thelayer of insulative material 24.

[0022] The layer of concrete 22 may preferably be formed by pouring thefluid concrete into a space 23 formed between the layer of insulative 24and a form 32 (see FIG. 6), or the like, which may be made of aluminum.The layer 22 may comprise a conventional cement of the sort which iswell known to the routineers in the art. The layer 24 of insulativematerial may generally be in the form of pre-formed panels 25 (see FIG.7) of expanded polystyrene or the like, and each panel 25 may desirablybe rectangular in shape with dimensions, for example, of 4 feet by 8feet, and the same may have a uniform thickness, for example, of one totwo inches. Such panels are conventional and well known in the field ofinsulated concrete walls. Typically, each panel 25 has opposing,generally parallel side edges and opposing, generally parallel upper andlower edges, all of which present generally planar edge surfaces wherebythe panels may be placed flush with opposing panels, as shown in FIG. 7,to form a substantially continuous layer of insulative material whichmay be coextensive in size with the concrete layer of the insulatedwall. Although an expanded or foamed polystyrene is a preferred materialfor the layer 24, other types of insulative panels or layers may beused, so long as the material chosen is capable of being supported bysome sort of tie assembly which provides support during the constructionof the wall. Tie assemblies of the sort illustrated in the '830 patentmentioned above may desirably be used for this purpose.

[0023] The wall 20 also includes an attachment element 34 as shown inFIG. 1. Although only a single attachment element 34 is shown in thedrawings, it will be appreciated by those skilled in the art that aninsulated wall, such as the wall 20, may desirably include a pluralityof attachment elements 34 positioned strategically so that a piece ofdecorative and/or finishing material may be attached to the wall 20. Forexample, siding, brick ties, additional insulation, pressboard and/orsoffits may be attached to the wall 20 using the attachment elements 34.

[0024] Withe reference to FIGS. 2 and 3, it can be seen that eachattachment element 34 includes an elongated body member 36 and anelongated face plate 38. The face plate 38 and the body member 36 maydesirably be in respective non-parallel planes which are transverse toone another and ideally perpendicular as shown. The body member 36 maypreferably be integrally attached to the face plate 38 at a centrallocation on the latter, as shown, such that the attachment element 34 ismonolithic and has a uniform, regular, continuous T-shaped transversecross-sectional configuration. This shape facilitates forming of theattachment element 34 by a conventional extrusion process. For example,a 12 foot length may be extruded and thereafter cut into 2 inch lengthsto present the individual attachment elements 34. To accommodate theextrusion process, the attachment elements may desirably be formed froma synthetic resin, preferably an extrudable thermoplastic material, andideally a UV resistant plastic such as polyvinyl chloride (PVC). Forpurposes of the present invention, the material simply needs to haveappropriate properties for receiving and retaining a fastener such as ascrew.

[0025] The elongated body member 36 has a first portion 40 and a secondportion 42. The portions 40 and 42 are preferably integrally connectedto one another and the same are positioned longitudinally of one anotheralong the length of the member 36 as shown. The face plate 38 isattached to the end 44 of the second portion 42. As can be seen viewingFIG. 3, first portion 40 of body member 36, is desirably in the form ofa generally planar sheet 44 which has opposed surfaces 46 and 48.Portion 40 preferably has a plurality of ideally parallel ribs or flutes50 which extend laterally outwardly from each surface 46, 48, and theseribs or flutes 50 desirably are provided with rounded outer surfaces 52so as to reduce localized stresses in the concrete layer 22 when portion40 is embedded in concrete as will be explained hereinafter. Portion 40also has an anchor segment 54 which includes opposed wings 56. Anchorsegment 54 is desirably located at a distance from face plate 38 whichis essentially the same as the thickness of the insulation layer 24, andthe same is provided with beveled surfaces 58 at the distal ends of thewings 56 so as to present a dovetail configuration.

[0026] With reference again to FIG. 1, it can be seen that portion 40 ofbody member 36 is embedded in concrete layer 22 with segment 54positioned at face 26. Portion 42 extends outwardly away from face 26and through a closed slot 60 which extends completely through thethickness of insulation layer 24. Face plate 38 is essentially in thesame plane as outer surface 30 of insulation layer 24.

[0027] As mentioned above, insulative layer 24 is desirably made up of aplurality of panels 25 (see FIG. 7) formed from an expanded polystyrenematerial and such material ideally is heat deformable. Thus, the slot 60may be formed in the center of the insulative layer 24 using a heatedknife or the like. The relative dimensions of the slot 60 and the bodymember 36 must be such that the entirety of the body member 36 may bepushed through the slot 60 during construction of the wall 20. Desirablythe width of slot 60, when it is first formed, may be less than theoverall width of the portion 42, whereby the ribs 50 and the wings 56may crush the foam structure of the layer 24 inside the slot as the bodymember is pushed therethrough. This will facilitate the provision of atight fit between the inside of the slot 60 and portion 42 of bodymember 36 after the installation of the attachment element 34 in layer24.

[0028] The relative dimensions of the outer periphery 62 of the slot 60at the outer surface 30 should ideally be such that further movement ofthe body member 36 through slot 60 is prevented when faceplate 38reaches the plane of surface 30. That is to say, the faceplate 38desirably extends laterally outwardly from the outer end 44 of thesecond portion 42 of body member 36 across outer surface 30 and beyondthe outer periphery 62 of the slot 60. In this regard, it is to be notedthat face plate 38 is provided with beveled surfaces 64 at its outboardedges 66. These beveled surfaces 64 permit the face plate 38 to beforced into the expanded polystyrene material at outer surface 30 duringassembly so that the outer surface 68 of the face plate 38 isessentially co-planar with outer surface 30.

[0029] A method of constructing an insulated concrete wall structuresuch as the structure 20 is illustrated in FIGS. 5 and 6. The methodutilizes an attachment element such as the element 34 and involves theforming of one or more slots 60 in a panel 25 of insulative materialsuch that the slots 60 each extend through the entire thickness of thepanel 25 between the outer surface 30 of the panel 25 and the innersurface 28 thereof. In accordance with the preferred aspects of theinvention, the insulative material of the layer 24 may be heat formableand each slot 60 therein may be formed by hand or by a machine using aheated knife.

[0030] The body member 36 of the attachment element 34 is inserted intoa corresponding slot 60 as illustrated in FIG. 5 and same is pushedentirely through the slot 60 until the attachment element assumes theposition shown in FIG. 6 with the first portion 40 extending outwardly apreselected distance from the inner surface 28 of the panel 25 ofinsulative material and with the face place 38 against the outer surface30 of the panel 25. Preferably, an aluminum form 32 (shown schematicallyin FIG. 6) may be positioned in spaced relationship to the inner surface28 of the panel 25 leaving a space 23 therebetween. The space 23 maythen be filled with fluid concrete in such a way that the first portion40 of the body member 36 is completely surrounded by the fluid concrete.The concrete is then allowed to set to thereby form an insulatedconcrete wall structure 20 in which the inner surface 28 of the panel 25of insulative material is against the hardened concrete, the firstportion 40 of the body member 36 of the attachment element 34 isembedded in the hardened concrete, the second portion 42 of the bodymember 36 extends through the slot 60, and the face plate 38 of theattachment element 34 extends across the outer surface 30 of the panel25 of insulative material. It should also be noted that the anchorsegment 54 is configured so that the first portion 40 is retained in thehardened concrete. To this end, the beveled surfaces 58 at the distalends of wings 56 provide triangular voids 73 which fill with fluidconcrete when the space 23 is filled.

[0031] It should be noted, with reference to FIG. 6, that a secondaluminum form 74 may be used if desired to hold the panel 25 in positionduring the application of the fluid concrete to space 23. After theconcrete filling space 23 has hardened, the forms 32 and 74 may beremoved in a conventional manner, and a piece of a finishing and/ordecorative material 76 may be secured to wall structure 20 (see FIG. 4)by extending a fastener, such as a screw 78, through the finishingand/or decorative material 76 and into the face plate 38 of theattachment element 34.

[0032] Referring to FIG. 7, the layer 24 comprises a plurality of panels25. The panels may each have one or more slots 60 (not seen in FIG. 7because they are behind the face plates 38) formed therein at variouslocations, as might be dictated by the exigencies of a givenapplication, and a respective attachment element 34 may be positioned ineach of the slots 60 as shown. Of course, the attachment elements 34 mayall be positioned in their respective slots 60 prior to the applicationof the fluid concrete which hardens to present the layer of concrete 22.

[0033] From the foregoing it will be seen that this invention is onewell adapted to attain all ends and objects herein above set forthtogether with the other advantages which are inherent to the structure.

[0034] It will be understood that certain features and subcombinationsare of utility and may be employed without reference to other featuresand subcombinations. This is contemplated by and is within the scope ofthe claims.

[0035] Since many possible embodiments may be made of the inventionwithout departing from the scope thereof, it is to be understood thatall matter herein set forth or shown in the accompanying drawings is tobe interpreted as illustrative, and not in a limiting sense.

I claim:
 1. An attachment element for use with a concrete wallconstruction that includes a layer of concrete and a layer of aninsulative material that is held against a face of said layer ofconcrete, said layer of insulative material having an inner surfacewhich is in contact with said face and an outer surface which is spacedfrom said face, the concrete of said layer thereof being characterizedby having been initially fluid and having hardened with said facethereof in said contact with said inner surface of the layer ofinsulative material, said attachment element comprising: an elongatedbody member having a first portion that is adapted and arranged forembedment in said layer of concrete as the latter hardens and a secondportion positioned longitudinally of the body member from said firstportion, said second portion being adapted and arranged so as to extendoutwardly from said face and through a closed slot formed in said layerof insulative material, said slot having an outer periphery at saidouter surface; and an elongated face plate attached to said secondportion adjacent an outer end of the latter, said face plate beingpositioned so as to extend transversely of said body member and beingadapted and arranged at said outer surface of said layer of insulativematerial in a position to extend laterally outwardly away from said bodymember and across said outer surface beyond said periphery of said slot,the entirety of said attachment element other than said face plate beingsmall enough in size to permit insertion thereof through said slotduring use.
 2. An attachment element as set forth in claim 1, whereinsaid member and said plate are integrally connected.
 3. An attachmentelement as set forth in claim 1, wherein said portions of the bodymember are integrally connected.
 4. An attachment element as set forthin claim 1, wherein said element is monolithic.
 5. An attachment elementas set forth in claim 1, wherein said element has a generally T-shapedtransverse cross-sectional configuration.
 6. An attachment element asset forth in claim 1, wherein said face plate is formed from a materialthat is adapted for receiving and retaining a fastener.
 7. An attachmentelement as set forth in claim 6, wherein said material is a syntheticresin material.
 8. An attachment element as set forth in claim 4,wherein said element is formed from a material that is adapted forreceiving and retaining a fastener.
 9. An attachment element as setforth in claim 8, wherein said material is a synthetic resin material.10. An attachment element as set forth in claim 9, wherein said materialis an extendable thermoplastic material.
 11. An attachment element asset forth in claim 7, wherein said material is an extrudablethermoplastic material.
 12. An attachment element as set forth in claim1, wherein said second portion of the body member is in the form of asheet having opposed surfaces.
 13. An attachment element as set forth inclaim 12, wherein said sheet is generally planar in configuration. 14.An attachment element as set forth in claim 12, wherein is included oneor more ribs which protrude laterally outwardly from a surface of saidsheet.
 15. An attachment element as set forth in claim 14, wherein saidribs have generally rounded outer surfaces.
 16. An attachment element asset forth in claim 1, wherein said second portion includes an anchorsegment located at the face of the concrete layer, said anchor segmentbeing adapted and configured to retain said second portion in saidconcrete.
 17. An attachment element as set forth in claim 12, whereinsaid second portion includes an anchor segment located at the face ofthe concrete layer, said anchor segment being adapted and configured toretain said second portion in said concrete.
 18. An attachment elementas set forth in claim 17, wherein said anchor segment includes a wingwhich extends laterally outwardly from a surface of the sheet.
 19. Anattachment element as set forth in claim 18, wherein said wing includesa beveled surface at an outer edge thereof which defines a dovetailpermitting the wing to be embedded in the layer of concrete duringconstruction.
 20. An attachment element as set forth in claim 14,wherein said second portion includes an anchor segment located at theface of the concrete layer, said anchor segment being adapted andconfigured to retain said second portion in said concrete.
 21. Anattachment element as set forth in claim 20, wherein said anchor segmentincludes a wing which extends laterally outwardly from a surface of thesheet.
 22. An attachment element as set forth in claim 21, wherein saidwing includes a beveled surface at an outer edge thereof which defines adovetail permitting the wing to be embedded in the layer of concreteduring construction.
 23. A concrete wall structure comprising: a layerof concrete having a face; a layer of an insulative material that isretained against the layer of concrete, said layer of insulativematerial having an inner surface which faces the face of said layer ofconcrete and an outer surface that is spaced from the concrete layer,there being at least one closed slot extending through the thickness ofthe layer of insulative material from the inner surface to the outersurface, said slot having an outer periphery at said outer surface; andan attachment element as set forth in claim 1, said first portion of thebody member being embedded in said layer of concrete, said secondportion of the body member protruding outwardly of the layer of concretefrom said face and through said slot, and said elongated face plateextending transversely of said body member across the outer surface ofthe layer of insulative material.
 24. A concrete wall structure as setforth in claim 23, wherein said layer of insulative material comprisesat least one panel having opposed side edges and opposed top and bottomedges, and said slot is positioned in spaced relationship relative tosaid edges.
 25. A concrete wall structure as set forth in claim 24,including a material applied against said outer face of the panel ofinsulative material and secured thereto at least in part by a fastenerextending into the face plate.
 26. A method of constructing an insulatedconcrete wall structure comprising: providing an attachment element asset forth in claim 1; forming at least one slot in a panel of insulativematerial having opposed first and second surfaces, said slot extendingthrough said panel between said surfaces; inserting the body member ofthe element through said slot so that the first portion extendsoutwardly a preselected distance from the first surface of the panel ofinsulative material and the face place is against the second surface ofthe panel of insulative material; applying a layer of fluid concreteagainst said first surface in a position where the first portion of bodymember is surrounded by the fluid concrete; allowing the concrete to setto thereby form an insulated concrete wall structure in which the firstsurface of the panel of insulative material is against the concrete, thefirst portion of the body member of the attachment element is embeddedin the hardened concrete, the second portion of the body member of theattachment element extends through the slot, and the face plate of theattachment element extends across the second face of the panel ofinsulative material.
 27. A method as set forth in claim 26, includingsecuring a finishing and/or decorative material to said wall structureby extending a fastener through said finishing and/or decorativematerial and into the face plate of the attachment element.
 28. A methodas set forth in claim 26, wherein the insulative material is heatformable and said forming the slot comprises applying heat to theinsulative material.
 29. A method as set forth in claim 26, includingforming a plurality of said slots in said panel and positioning one ofsaid attachment elements in each of said slots prior to the applicationof said layer of fluid concrete.